The portlights need to be accurately located on the outside of the cabin sides to match the existing portlight cutouts in the doublers.
A ball bearing at the top of the router bit follows the outline of this pattern for the starboard aft portlight. The pattern will be flipped to make the cutout for the port aft portlight.
A backing ring, shown here on the port side, adds thickness/strength for the portlight cutout.
The starboard aft portlight ring glued in with corner fillets.
Starboard aft portlight cutout partially routed out.
Starboard aft cutout completed.
Aft port side completed. These cutouts allow for fitting the flat laminated glass portlights into the curved cabin sides.
